Mitsubishi 2033D SERIES User manual

MITSUBISHI ELECTRIC 2033D SERIES UPS

MITSUBISHI ELECTRIC AUTOMATION, INC.

UNINTERRUPTIBLE POWER SUPPLY SYSTEM

2033D SERIES

OWNERS / TECHNICAL MANUAL

Revision 1.3: December 18, 2003

ALN-H0963

23D_00s.doc MITSUBISHI ELECTRIC 2033D SERIES UPS

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Preface

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TABLE OF CONTENTS

LIST OF TABLES ............................................................................................... iii

LIST OF FIGURES ............................................................................................ iv

HOW TO USE THIS MANUAL ........................................................................... v

1.0 INTRODUCTION ....................................................................................... 1-1

1.1 GENERAL ................................................................................................. 1-3

1.2 DEFINITIONS ............................................................................................ 1-4

1.3 OVERVIEW ............................................................................................... 1-5

1.4 SPECIFICATIONS .................................................................................... 1-11

2.0 OPERATOR CONTROLS AND INDICATORS ......................................... 2-1

2.1 LED DISPLAY ........................................................................................... 2-2

2.2 MBP LAMP....................................................................................................2-2

2.3 EPO BUTTON ........................................................................................... 2-2

2.4 LIQUID CRYSTAL DISPLAY ..................................................................... 2-3

2.5 EXTERNAL SIGNAL TERMINAL BLOCK ................................................. 2-8

2.6 EXTERNAL COMMUNCATION CONNECTOR .......................................... 2-13

3.0 INSTALLATION AND OPERATION ......................................................... 3-1

3.1 TRANSPORTATION AND INSTALLATION .............................................. 3-1

3.2 INSTALLATION PROCEDURE ................................................................. 3-1

3.3 PROCEDURE FOR CABLE CONNECTIONS ........................................... 3-3

3.4 OPERATING PROCEDURES ................................................................... 3-12

3.5 MAINTENANCE BYPASS SET-UP PROCEDURES ....................................3-13

4.0 RESPONSE TO UPS FAILURE ................................................................ 4-1

5.0 PARTS REPLACEMENT .......................................................................... 5-1

6.0 FAULT CODES ......................................................................................... 6-1

7.0 WARRANTY & OUT OF WARRANTY SERVICE ..................................... 7-1

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iii

List of Tables

Table 1.1 Power Specifications ................................................................... 1-11

Table 1.2 UPS Module Information.............................................................. 1-11

Table 1.3 Detail of Specifications ................................................................ 1-12

Table 1.4 Rating of Contactor and Fuses .................................................... 1-13

Table 3.1 How to Transport and Install the System..................................... 3-1

Table 3.2 List of UPS Weights (lb.).............................................................. 3-1

Table 3.3 Type and number of Battery ........................................................ 3-2

Table 3.4 Maximum Permitted Fault Current............................................... 3-3

Table 3.5 Recommended Cable Size and Torque Requirements ............... 3-5

Table 3.6 Crimp Type Compression Lug ..................................................... 3-6

Table 6.1 Fault Code ................................................................................... 6-2

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List of Figures

Figure 1.1 Single Line Diagram-Normal Operation .................................................... 1-5

Figure 1.2 Single Line Diagram-Bypass Operation.................................................... 1-6

Figure 1.3 Single Line Diagram-Battery Operation .................................................... 1-7

Figure 1.4 UPS Parts Location .................................................................................. 1-8

Figure 1.5 UPS Parts Location (Continued)............................................................... 1-9

Figure 1.6 External I/F circuit PCB IOAU-05.............................................................. 1-9

Figure 2.1 Operation/Display Panel ........................................................................... 2-1

Figure 2.2 Main Screen ............................................................................................. 2-3

Figure 2.3 Start/Stop Screen ..................................................................................... 2-4

Figure 2.4 PIN Protection Screen .............................................................................. 2-4

Figure 2.5 Bypass Voltage Abnormal Message Screen............................................. 2-4

Figure 2.6 Measurement Screen ............................................................................... 2-4

Figure 2.7 Setup Screen............................................................................................ 2-5

Figure 2.8 Log Select Screen .................................................................................... 2-5

Figure 2.9 Event Log Screen ..................................................................................... 2-5

Figure 2.10 Battery Log Screen ................................................................................. 2-6

Figure 2.11 Main Screen (Battery Operation) ............................................................ 2-6

Figure 2.12 Measurement Screen (Battery Operation) ................................................ 2-6

Figure 2.13 Main Screen (Fault Indication) ................................................................ 2-7

Figure 2.14 Message Screen ..................................................................................... 2-7

Figure 2.15 External Signal Terminal Block................................................................. 2-8

Figure 2.16 Control Wiring for External Contacts ........................................................ 2-10

Figure 2.17 Remote "Start" Contact Connections........................................................ 2-11

Figure 2.18 External communication connector........................................................... 2-13

Figure 3.1 UPS Terminal Designation ...................................................................... 3-7

Figure 3.2 Diagram of input/output bus bars and terminal blocks ............................ 3-8

Figure 3.3 Diagram of Power Wire Connect (Parallel Connection) .......................... 3-10

Figure 3.4 Diagram of Power Wire & Control Wire Connect (Parallel Connection ) . 3-11

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How to use this Manual

This manual is designed for ease of use, giving the user easy and quick reference to

information.

This manual uses notice icons to draw attention to the user important information regarding the

safe operation and installation of the UPS. The notice icons used in this manual are explained

below, and should be taken into account and adhered to whenever they appear in the text of

this manual.

Warning: A warning notice icon conveys information provided to protect

the user and service personnel against hazards and/or possible equipment

damage.

Caution: A caution notice icon conveys information provided to protect

the user and service personnel against possible equipment damage.

Note: A Note notice icon indicates when the user should make a reference of

information regarding the UPS operation, load status and display status.

Such information is essential if Mitsubishi field service group assistance and

correspondence is required.

Safety Recommendations: If any problems are encountered while following this manual,

Mitsubishi field service group assistance and correspondence is recommended.

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1.0 INTRODUCTION

Your Mitsubishi Uninterruptible Power Supply System (UPS) is designed to provide many

years of reliable protection from power failure, brown-outs, line noise, and voltage transients.

To ensure optimum performance of the equipment, follow the manufacturer's instructions. This

manual contains descriptions required to operate the UPS. Please read this manual carefully

and retain it for future reference.

This manual contains important instructions for the 2033D Series Uninterruptible Power Supply

System that should be followed during installation and maintenance of the UPS and batteries.

Lethal voltages exist within the equipment during operation. Observe all

warning and cautions in this manual. Failure to comply may result in

serious injury or death. Obtain qualified service for this equipment as

instructed.

IMPORTANT SAFETY INSTRUCTIONS

RETAIN THESE INSTRUCTIONS

WARNING 1

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This UPS does not include a Bypass input circuit breaker (MCCB) to protect bypass

circuit. Bypass input circuit breaker (MCCB) are to be field supplied and installed.

Recommended Breaker (MCCB)'s Specifications are as follows:

Capacity (kVA) Bypass Voltage (Vac) Bypass Rating (Aac)

Recommended

Breaker (Aac)

30 480 36 45

50 480 60 80

80 480 96 125

AC input and AC output over current protection and disconnect devices shall be field

supplied and installed. DC output over current protection and disconnect device shall

be field supplied and installed. The over current protection device shall be rated as

indicated in TABLE 1.4.

WARNING 2

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1.1 GENERAL

The Mitsubishi 2033D Series UPS is designed to provide continuous and clean electrical

power to a critical load. Additionally the UPS monitors power conditions affecting the load.

In the event of an input power failure, the UPS will supply power to the critical load for the

specified battery time.

If the input power is not restored promptly, back up power from the UPS battery permits

the orderly shutdown of equipment supported by the UPS. The UPS is simple to start-up,

operate and maintain.

The 2033D Series UPS is available in three (3) kVA sizes-30, 50 and 80kVA, and also in

two (2) output voltages - 208V and 480V. Specifications for each kVA and voltage model

appear in Section 1.4. 30kVA model have batteries included in the UPS module cabinet.

50 and 80kVA models have external batteries. The principles of operation described herein

are applicable to all models.

This manual provides an overview of the 2033D Series components and their functions.

The appearance and purpose of operator controls and indicators is described with

procedures for operation, start-up, shutdown and basic maintenance included.

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1.2 Definitions

UNINTERRUPTIBLE POWER SUPPLY SYSTEM (UPS) - All components within the UPS

Module Cabinet and associated batteries that function as a system to provide continuous,

conditioned AC power to a load. This is sometimes referred to as the "System".

UPS MODULE CABINET - The metal enclosure which contains the Converter, the Inverter,

the Chopper, the Static Transfer Switch, the Internal Bypass line, the operator controls,

and the internal control system required to provide specified AC power to a load.

UPS MODULE - The Converter and Inverter assemblies which, under the direction of the

internal control system and operator controls, provide specified AC power to a load.

CONVERTER/BOOSTER - The UPS components which contain the equipment and

controls necessary to convert input AC power to regulated DC power required for battery

charging and for supplying power to the Inverter.

INVERTER - The UPS components which contain the equipment and controls necessary

to convert DC power from the Converter, or the battery, to AC power required by the

critical load.

CHOPPER - The UPS components which contain the equipment and controls necessary

to charge the battery and supply power to the Inverter from battery.

STATIC TRANSFER SWITCH - The device which connects the critical load to the bypass

line when the UPS module cannot supply continuous power.

BYPASS LINE - The line which conducts electricity directly from the input power source to the

critical load during Maintenance or whenever the UPS is not completely operational.

INPUT POWER - Power provided by the electrical utility company, or auxiliary generator,

which is connected to the UPS for supplying the critical load.

BATTERY - The rechargeable battery strings which supply DC power to the inverter to

maintain continuous AC power to the load during AC input power failure conditions

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1.3 Overview

The UPS provides two power paths between the utility source and the critical load.

Figure 1.1 shows the path for normal operation, with the load powered from the inverter.

Figure 1.2 shows the path for bypass operation, with the load supplied through the static

bypass line.

Figure 1.3 shows the path for battery operation, with the load supplied from the inverter.

A) Normal Operation.

FIGURE 1.1 Single Line Diagram - Normal Operation. Load powered by inverter

During normal operation, the path through the inverter is used to power the load.

Referring to Figure 1.1: Input AC power is converted to DC by the Converter. DC power is

utilized to charge the UPS battery and to provide power to the Inverter. The Inverter

converts the DC power to clean AC power to supply the critical load.

The conversion - inversion process eliminates any voltage transients or fluctuations

existing in the input power before it reaches the critical load.

* The AC Bypass Input circuit breaker (MCCB) for protection of the UPS and cables are field

supplied and field installed. (See WARNING 2 on page 1-2)

UPS Module

Power Flow

Not in Use

AC input

CB

FB

72B

52RS

CONVERTER

INVERTER

Output

52C

52RC

FI

FO

BATTERY

User

su

pp

lied

52CS

Maintenance

Bypass

Switch

50kVA, 80kVA:

External Battery

Static Transfer

Switch

CB

AC Bypass

In

put

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B) Internal Static Bypass Line

FIGURE 1.2 Single Line Diagram- Bypass Operation. Load fed through static bypass line.

Referring to Figure 1.2, the Internal Static Bypass line is a Hard wired line through Static

Transfer Switch which supplies the critical load with unconditioned input power. The

purpose of this line is to route power to the critical load while the UPS module is

de-energized during Start-up before the system is fully operational.

The internal control system determines the operation of the two paths, with the load

powered from the inverter being the normal operation.

UPS Module

Power Flow

Not in Use

CB

FB

72B

52RS

CONVERTER

INVERTER

Output

52C

52RC

FI

FO

BATTERY

User

su

pp

lied

52CS

Maintenance

Bypass

Switch

50kVA, 80kVA:

External Battery

Static Transfer

Switch

CB

AC Bypass

In

put

AC input

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C) Inverter supply at battery operation

FIGURE 1.3 Single Line Diagram - Battery Operation

Referring to Figure 1.3: In the event of AC input source failure or interruption, the

converter will de-energize and the battery will immediately discharge and supply DC

power to the inverter to maintain continuous AC power to the load. This operation will

continue until:

a) The battery capacity expires and the inverter turns off, or

b) Input power is restored after which the converter will power the inverter and critical

load and simultaneously recharge the batteries.

A fully charged battery will provide power for the specified time at the rated load, or longer,

at a reduced load.

When power is restored after a low battery shutdown, the converter automatically restarts

operation, recharges the batteries and the Inverter is automatically restarted without

operator intervention. Load is automatically assumed by the inverter without operator

intervention.

The power drawn by the load is equally shared between all system UPS during battery

operation.

UPS Module

Power Flow

Not in Use

AC input

CB

FB

72B

52RS

CONVERTER

INVERTER

Output

52C

52RC

FI

FO

BATTERY

User

su

pp

lied

52CS

Maintenance

Bypass

Switch

50kVA, 80kVA:

External Battery

Static Transfer

Switch

CB

AC Bypass

In

put

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FIGURE 1.4-a UPS Parts Location (30kVA)

FIGURE 1.4-b UPS Parts Location (50kVA, 80kVA)

2. Grounding Bar

52C

UPS module

FRONT VIEW

Inverter

unit

72B

52CS

1. External I/F

Circuit PCB

IOAU-05

Converter Unit

52RC

Chopper Unit

52RS

GND GND ELEC

TERM

DC

Capacitor

Parallel

I/F PCB

2. Grounding Bar

52RS

UPS module

FRONT VIEW

Inverter

unit

52RC

52CS

1. External I/F

Circuit PCB

IOAU-05

Converter

Chopper Unit

72B

52C

GND

GND ELEC TERM

Parallel

I/F PCB

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FIGURE 1.5 UPS Parts Location (Continued)

FIGURE 1.6 External I/F PCB IOAU-05

UPS module

BACKSIDE OF FRONT DOOR(Right side)

|

FAULT

RESET

|

MAINTENANCE

BUTTON

|

TEST

SWITCH

|

BOOT

SWITCH

SYNC.LED

INVERTER

START

|

INVERTER

STOP

|

8

7

9

10

5

6

IOAU-05

3. External Contact Signal Terminal

4. RS232C D-sub Connector

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Description of Figures 1.4, 1.5, and 1.6:

1. External I/F Board (IOAU-05) : FOR SERVICE PERSONNEL ONLY (FIGURE 1.6):

- (3) External contact signal terminal

- (4) RS232C communication connector

2. Grounding Bar (E)

3. External Contact Signal Terminal Block - Terminal block to connect contact signal

input/output lines to and from the external devices. Refer to Figure 2.15 section 2.5 for

details.

4. RS232C Communication Connector - Refer to Figure 2.18 section 2.6 for details.

5. “INVERTER” START Switch - This switch is used to transfer the UPS from static bypass

to inverter during maintenance purposes. Transfers will lock-out if the bypass voltage is

more than +10%,-10% of nominal.

* Uninterrupted switching is made at the time of synchronous operation. Switching is impossible at

the time of asynchronous operation.

6. “INVERTER STOP” Switch - This switch is used to transfer the UPS from inverter to static

bypass during maintenance purposes. Do not operate it under normal operation. Transfers

will lock-out if the bypass voltage is more than +10%,-10% of nominal.

* Uninterrupted switching is made at the time of synchronous operation. Switching is impossible at

the time of asynchronous operation.

7. “FAULT RESET” Switch (FOR SERVICE PERSONNEL ONLY) - This switch resets

errors resulting from alarm conditions. (Do not operate this switch while inverter and

converter are in operation.)

8. Maintenance (Set) Button (FOR SERVICE PERSONNEL ONLY) - This switch sets the

UPS menu parameters.

9. “Test mode” Switch (FOR SERVICE PERSONNEL ONLY) - This switch changes system

operation to the test-mode. (This switch should not be operated by personnel other than

an Authorized Service Engineer).

10. “BOOT” Switch (FOR SERVICE PERSONNEL ONLY) - This switch boots the processor

in the main control circuit resulting from alarm conditions. (Do not operate this switch

while inverter and converter are in operation).

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1.4 Specifications

The UPS name plate displays the rated kVA as well as nominal voltages and currents. The

name plate is located on the inside of the UPS front door.

TABLE 1.1 Power Specifications

Rated output

Power

Input voltage

3 phase / 3 wire

Bypass input voltage

3 phase / 3 wire

Output voltage

3 phase / 3 or 4 wire

30kVA / 24kW

50kVA / 40kW

80kVA / 64kW

480V

208V or 480V

TABLE 1.2 UPS Module Information

UPS

[kVA]

CABLE

ENTRY

WIDTH

[in / mm]

DEPTH

[in / mm]

HEIGHT

[in / mm]

WEIGHT

[lb./ kg]

HEATING

[kBTU/h]

30 BOTTOM 33.9 / 860 31.5 / 800 70.9 / 1800 2060 / 930 9.1

50 BOTTOM 33.9 / 860 31.5 / 800 70.9 / 1800 1810 / 820 13.5

80 BOTTOM 33.9 / 860 31.5 / 800 70.9 / 1800 1990 / 900 21.6

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TABLE 1.3 Detail of Specifications

Rated Output kVA 30 50 80

Rated Output kW 24 40 64

AC INPUT

Configuration 3 phase, 3 wire

Voltage 480 V +15% to -15% (-30% can be operated)

Frequency 60 Hz (45.4Hz to 65Hz)

Reflected Current THD 4% typ. at 100% load; 7% typ. at 50% load

STATIC BYPASS INPUT

Configuration 3 phase, 3 wire

Voltage 480 V +/-10%

Frequency 60 Hz

BATTERY

Type Lead Acid

Ride Through Application Specific

Nominal Voltage 480 Vdc

Minimum Voltage 401 Vdc

Number of Cells 240

AC OUTPUT

Configuration 3 phase, 4 wire

Voltage 120/208 V, 277/480 V

Voltage Stability +/-1%

Frequency 60 Hz

Frequency Stability +/-0.05% in free running mode

Power Factor 0.8 nominal

Power Factor range 0.8 - 1.0 lagging (within output kW rating)

Voltage THD 2% typical THD at 100% Linear Load

5% typical THD at 100% non-linear load

Transient Response +/-3% at 100% load step

+/-1% at loss/return of AC power

+/-3% at load transfer to/from static bypass

Transient Recovery 16.6ms

Inverter Overload 125% for 10 minutes, 150% for 1 minute

System Overload 1000% for 1 cycle (with bypass available)

Bypass Overload 150% for 1 minutes

ENVIRONMENTAL

Cooling Forced Air

Operating Temperature

32ﾟF ~ 104ﾟF (0ﾟC - 40ﾟC)

Recommended 68ﾟF - 86ﾟF (20ﾟC - 30ﾟC)

Relative Humidity 5% ~ 95% Non Condensing

Altitude 0 ~ 9000 feet No Derating

Location Indoor (free from corrosive gases and dust)

(PCB conformally coated for use in industrial environment)

Paint Color Munsell 5Y7/1 (Beige)

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TABLE 1.4 Rating of Contactors and Fuses

OUTPUT CAPACITY OF EQUIPMENT

2033D-B 2033D-A 2033D-B

30VA 50kVA 50kVA 80kVA

NUMBER APPLICATION

208V 480V 208V 480V 208V 480V 208V 480V

52RC AC Input

Contactor

60A 100A

52C AC Output

Contactor

60A 100A

52RS Bypass Contactor 60A 100A

72B Battery Disconnect

Contactor

80A 135A 200A

C

O

N

T

A

C

T

O

R

88RC Control circuit

Contactor

90A

FIU, FIV, FIW Inverter

Output Fuse

80A/660V 140A/660V

FOU, FOV, FOW Inverter

Output Fuse

80A/660V 140A/660V

FUA, FUB, FUC Control

Power Fuse

30A/600V

FSU, FSV, FSW

(Option)

Bypass

Input Fuse

140A/660V 280A/660V

FBP, FBN DC Input

Fuse

125A/1250V 200A/1250V 350A/1250V

FZS1, 2, 3 Bypass Input

ZNR Fuse

16A/500V

FBS1, 2 Control

Power Fuse

10A/600V

FUF1, 2 Control

Power Fuse

10A/600V

F

U

S

E

FZR1, 2, 3 AC Input

ZNR Fuse

16A/500V

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2.0 OPERATOR CONTROLS AND INDICATORS

The 2033D Series operator controls and indicators are located as follows:

Circuit breakers and contactors: Inside the module

UPS status indicators: Outside of front door

FIGURE 2.1 Operation/Display Panel (Front panel)

LOAD ON

INVERTER

BATTERY

OP.

LOAD ON

BYPASS

OVER LOAD

LCD

FAULT

UPS

FAULT

EMERG.STOP

1

2

6

3

5

4

9

8

MBP

540

V

52RC 52C

72B

STS

48A

7

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